Rolling Operation

Gears require a rolling operation after chamfering due to the plastic deformation caused by this operation and to eliminate the “burs” or swellings that form on the material.

Whilst burs on the gear face may be removed by deburring tool, those on the lead remain.

These burs, usually in the range of 0.05 – 0.07 mm, cause problems in subsequent grinding phases and actually put the grinding wheel at risk. At this point a rolling operation on the gears becomes necessary.

chamfering and deburring
Figure 7 Rolling requirement due to Swelling

The Samputensili method of chamfering-rolling uses a common chamfering/rolling tool (Patented) and a deburring tool to complete the chamfer-roll-deburr simultaneously.

Chamfering and deburring
Figure 8 Samputensili chamfer-rolling tool
Chamfering and deburring
Figure 9 Chamfering - Rolling - Deburring in simultaneous operation

Gears that are chamfered and rolled have been tested after heat treatment

  1. cracks do not form in the rolled area.
  2. the structure is normal and corresponds to all the structural characteristics of the material.

Tool Configuration – Options

Chamfering and deburring tools can be organized in various configurations for different types of gears, geared shafts and sprockets.

For example, cluster gears can be processed in a single operation with multiple chamfering and deburring tools organized as shown below.

Chamfering and deburring
Figure 10 Simultaneous Operation on 2 gears

Conclusion – Precision Gear Chamfering and Deburring

Gear chamfering and deburring is a key process technology in automotive powertrain for achieving smooth gear transmissions. Capability to produce strong accurate chamfers is essential. In addition, for gears that are later finished, a rolling operation can be integrated with chamfering and deburring.  Multiple Configuration options in tooling enable a solution for a wide variety of automotive gears.

TO BE CONTINUED….